Hoshizaki American, Inc. KM-1600MRF User manual

NO.:

ISSUED:

REVISED:

HOSHIZAKI

MODULAR CRESCENT CUBER

KM-1600MRF

KM-1600MRF3

SERVICE MANUAL

MODEL

73078

FEB. 19, 1999

DEC. 13, 2003

2

HOSHIZAKI AMERICA, INC.

618 Highway 74 South

Peachtree City, GA 30269

Attn: HOSHIZAKI Technical Support Department

Phone: 1-800-233-1940 Technical Service

(770) 487-2331

Fax: (770) 487-3360

NOTE: To expedite assistance, all correspondence/communication MUST include the following

information:

• Model Number

• Serial Number

• Complete and detailed explanation of the problem

IMPORTANT

Only qualified service technicians should attempt to service or maintain this icemaker.

No service or maintenance should be undertaken until the technician has thoroughly

read this Service Manual.

HOSHIZAKI provides this manual primarily to assist qualified service technicians in the

service and maintenance of the icemaker.

Should the reader have any questions or concerns which have not been satisfactorily

addressed, please call or write to the HOSHIZAKI Technical Support Department for

assistance.

3

CONTENTS

PAGE

I. SPECIFICATIONS .............................................................................................................5

1. KM-1600MRF (Remote air-cooled) ..............................................................................5

2. KM-1600MRF3 (3 Phase, Remote air-cooled).............................................................6

3. CONDENSING UNIT, URC-20F ..................................................................................7

II. GENERAL INFORMATION ...............................................................................................9

1. CONSTRUCTION ........................................................................................................9

KM-1600MRF, KM-1600MRF3 ...................................................................................9

2. CONTROLLER BOARD.............................................................................................10

[a] SOLID-STATE CONTROL ...................................................................................10

[b] CONTROLLER BOARD.......................................................................................10

[c] SEQUENCE .........................................................................................................15

[d] CONTROLS AND ADJUSTMENTS .....................................................................18

[e] CHECKING CONTROLLER BOARD...................................................................22

III. TECHNICAL INFORMATION........................................................................................23

1. WATER CIRCUIT AND REFRIGERANT CIRCUIT....................................................23

KM-1600MRF, KM-1600MRF3 .................................................................................23

2. WIRING DIAGRAM....................................................................................................24

[a] KM-1600MRF.......................................................................................................24

[b[ KM-1600MRF3.....................................................................................................25

3. TIMING CHART .........................................................................................................26

4. PERFORMANCE DATA.............................................................................................28

[a] KM-1600MRF.......................................................................................................28

[b] KM-1600MRF3.....................................................................................................29

IV. SERVICE DIAGNOSIS .................................................................................................30

1. NO ICE PRODUCTION..............................................................................................30

2. EVAPORATOR IS FROZEN UP................................................................................33

3. LOW ICE PRODUCTION...........................................................................................33

4. ABNORMAL ICE........................................................................................................34

5. OTHERS ....................................................................................................................34

Please review this manual. It should be read carefully before the icemaker is serviced or

maintenance operations are performed. Only qualified service technicians should service

and maintain the icemaker. This manual should be made available to the technician prior

to service or maintenance.

4

V. REMOVAL AND REPLACEMENT OF COMPONENTS ............................................... 35

1. SERVICE FOR REFRIGERANT LINES.................................................................... 35

[a] REFRIGERANT RECOVERY ............................................................................. 35

[b] EVACUATION AND RECHARGE....................................................................... 35

2. BRAZING .................................................................................................................. 36

3. REMOVAL AND REPLACEMENT OF COMPRESSOR ........................................... 37

4. REMOVAL AND REPLACEMENT OF DRIER.......................................................... 38

5. REMOVAL AND REPLACEMENT OF EXPANSION VALVE ................................... 39

6. REMOVAL AND REPLACEMENT OF HOT GAS VALVE AND LINE VALVE .......... 40

7. REMOVAL AND REPLACEMENT OF EVAPORATOR ............................................ 41

8. REMOVAL AND REPLACEMENT OF CONDENSING PRESSURE............................

REGULATOR (C.P.R.)............................................................................................ 42

9. REMOVAL AND REPLACEMENT OF THERMISTOR ............................................. 43

10. REMOVAL AND REPLACEMENT OF FAN MOTOR ................................................ 44

11. REMOVAL AND REPLACEMENT OF WATER VALVE............................................ 45

12. REMOVAL AND REPLACEMENT OF PUMP MOTOR............................................. 45

13. REMOVAL AND REPLACEMENT OF SPRAY TUBES ............................................ 46

VI. CLEANING AND MAINTENANCE INSTRUCTIONS................................................... 47

1. PREPARING THE ICEMAKER FOR LONG STORAGE........................................... 47

2. CLEANING AND SANITIZING PROCEDURES........................................................ 49

[a] CLEANING PROCEDURE.................................................................................. 49

[b] SANITIZING PROCEDURE ................................................................................ 52

3. MAINTENANCE........................................................................................................ 53

5

I. SPECIFICATIONS

1. KM-1600MRF

AC SUPPLY VOLTAGE 208-230/60/1 (3 wire with neutral for 115V)

AMPERAGE 18 A ( 5 Min. Freeze AT 104°F / WT 80°F)

MINIMUM CIRCUIT AMPACITY 30 A

MAXIMUM FUSE SIZE 30 A

APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)

PER 24 HR. Temp.(°F) 50 70 90

lbs./day ( kg/day ) 70 *1486 (674) 1438 (652) 1347 (611)

Reference without *marks 80 1450 (658) 1375 (624) 1270 (576)

90 1438 (652) *1323 (600) 1221 (554)

100 1411 (640) 1299 (589) 1128 (512)

SHAPE OF ICE Crescent Cube

ICE PRODUCTION PER CYCLE 28.6 lbs. (13 kg ) 1440 pcs.

APPROXIMATE STORAGE CAPACITY N/A

ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F

ELECTRIC W (kWH/100 lbs.) 3100 (5.9) 2800 (4.5)

WATER gal./24HR (gal./100 lbs.) 421 (31.8) 643 (43.3)

EXTERIOR DIMENSIONS (WxDxH) 30" x 27-3/8" x 41-1/2" (762 x 695 x 1055 mm)

EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)

WEIGHT Net 295 lbs. ( 134 kg ), Shipping 352 lbs. ( 160 kg )

CONNECTIONS - ELECTRIC Permanent - Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

3/8" ID Pipe

CUBE CONTROL SYSTEM Float Switch

HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer

ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe

COOLING WATER CONTROL N/A

BIN CONTROL SYSTEM Thermostat

COMPRESSOR Hermetic, Model CS20K6E-PFV

CONDENSER Air-cooled Remote, Condeser Unit URC-20F

EVAPORATOR Vertical type, Stainless Steel and Copper

REFRIGERANT CONTROL Thermostatic Expansion Valve

Condensing Pressure Regulator on URC-20F

REFRIGERANT CHARGE R-404A, 14 lbs. 12 oz. ( 6700 g )

( Icemaker 7 lbs. 1 oz. Cond. Unit 7 lb. 11 oz. )

DESIGN PRESSURE High 467 PSIG, Low 230 PSIG

P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal )

COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal )

REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch

LOW WATER PROTECTION Float Switch

ACCESSORIES -SUPPLIED N/A

-REQUIRED Ice Storage Bin, Remote Condenser Unit

OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 V

AMBIENT TEMP. 45 -100° F

WATER SUPPLY TEMP. 45 - 90° F

WATER SUPPLY PRESSURE 10 - 113 PSIG

DRAWING NO. (DIMENSION) 3A1026

We reserve the right to make changes in specifications and design without prior notice.

6

2. KM-1600MRF3

AC SUPPLY VOLTAGE 208-230/60/3

AMPERAGE 11 A ( 5 Min. Freeze AT 104°F / WT 80°F)

MINIMUM CIRCUIT AMPACITY 20 A

MAXIMUM FUSE SIZE 20 A

APPROXIMATE ICE PRODUCTION Ambient WATER TEMP. (°F)

PER 24 HR. Temp.(°F)507090

lbs./day ( kg/day ) 70 *1524 (691) 1467 (665) 1392 (632)

Reference without *marks 80 1480 (671) 1391 (631) 1319 (598)

90 1467 (665) *1328 (602) 1253 (569)

100 1453 (659) 1311 (594) 1185 (538)

SHAPE OF ICE Crescent Cube

ICE PRODUCTION PER CYCLE 28.6 lbs. (13 kg ) 1440 pcs.

APPROXIMATE STORAGE CAPACITY N/A

ELECTRIC & WATER CONSUMPTION 90/70°F 70/50°F

ELECTRIC W (kWH/100 lbs.) 2990 (5.4) 2850 (4.5)

WATER gal./24HR (gal./100 lbs.) 436 (32.8) 635 (41.7)

EXTERIOR DIMENSIONS (WxDxH) 30" x 27-3/8" x 41-1/2" (762 x 695 x 1055 mm)

EXTERIOR FINISH Stainless Steel, Galvanized Steel (Rear)

WEIGHT Net 295 lbs. ( 134 kg ), Shipping 352 lbs. ( 160 kg )

CONNECTIONS - ELECTRIC Permanent - Connection

- WATER SUPPLY Inlet 1/2" FPT

- DRAIN Outlet 3/4" FPT

3/8" ID Pipe

CUBE CONTROL SYSTEM Float Switch

HARVESTING CONTROL SYSTEM Hot Gas and Water, Thermistor and Timer

ICE MAKING WATER CONTROL Timer Controlled. Overflow Pipe

COOLING WATER CONTROL N/A

BIN CONTROL SYSTEM Thermostat

COMPRESSOR Hermetic, Model CS20K6E-TF5

CONDENSER Air-cooled Remote, Condenser Unit URC 20F

EVAPORATOR Vertical type, Stainless Steel and Copper

REFRIGERANT CONTROL Thermostatic Expansion Valve

Condensing Pressure Regulator on URC-20F

REFRIGERANT CHARGE R-404A, 14 lbs. 12 oz. ( 6700 g )

( Icemaker 7 lbs. 1 oz. Cond. Unit 7 lb. 11 oz. )

DESIGN PRESSURE High 467 PSIG, Low 230 PSIG

P.C. BOARD CIRCUIT PROTECTION High Voltage Cut-out ( Internal )

COMPRESSOR PROTECTION Auto-reset Overload Protector ( Internal )

REFRIGERANT CIRCUIT PROTECTION Auto-reset High Pressure Control Switch

LOW WATER PROTECTION Float Switch

ACCESSORIES -SUPPLIED N/A

-REQUIRED Ice Storage Bin, Remote Condenser Unit

OPERATING CONDITIONS VOLTAGE RANGE 187 - 253 V

AMBIENT TEMP. 45 -100° F

WATER SUPPLY TEMP. 45 - 90° F

WATER SUPPLY PRESSURE 10 - 113 PSIG

DRAWING NO. (DIMENSION) 3A1026

We reserve the right to make changes in specifications and design without prior notice.

7

3. CONDENSING UNIT

URC-20F

8

SPECIFICATIONS

MODEL: URC-20F

EXTERIOR

DIMENSIONS (W x D x H)

REFRIGERANT CHARGE

URC-20F

WEIGHT

CONNECTIONS

REFRIGERANT

ELECTRICAL

CONDENSER

HEAD PRESSURE CONTROL

AMBIENT CONDITION

Galvanized Steel

46 - 3/8" x 15 - 11/16" x 25 - 15/16"

(1178 x 398 x 659 mm)

R404A 7 lbs.11 oz. (3500 g)

Net 104 lbs. (47 kg)

Shipping 150 lbs. (52 kg)

One Shot Couplings (Aeroquip)

Permanent Connection

Air-cooled

Condensing Pressure Regulator

Min. -20°F - Max. +122°F

(-29°C to +50°C)

Outdoor use

9

II. GENERAL INFORMATION

1. CONSTRUCTION

KM-1600MRF, KM-1600MRF3

Spray Tube

Water Valve

Water Supply Inlet

Hot Gas Valve

Junction Box

Check Valve

Expansion Valve

Line Valve

Receiver Tank

Capacitor Box

(KM-1600MRF)

Transformer Box

(KM-1600MRF3)

Drier

Compressor

Cleaning Valve

Control Box

Control Switch

Bin Control

Thermostat

Float Switch

Water Pump

Evaporator

10

2. CONTROLLER BOARD

[a] SOLID-STATE CONTROL

1) A HOSHIZAKI exclusive solid-state control is employed in KM-1600MRF and

KM-1600MRF3 Modular Crescent Cubers.

2) A Printed Circuit Board (hereafter called “Controller Board”) includes a stable and high

quality control system.

3) All models are pretested and factory-adjusted.

[b] CONTROLLER BOARD

CAUTION

1. Fragile, handle very carefully.

2. A controller board contains integrated circuits, which are susceptible to

failure due to static discharge. It is especially important to touch the metal

part of the unit when handling or replacing the board.

3. Do not touch the electronic devices on the board or the back of the board to

prevent damage to the board.

4. Do not change wiring and connections. Do not misconnect K3, K4 and K5,

because the same connector is used for the Thermistor and Float Switch.

K4 is not connected.

5. Always replace the whole board assembly when it goes bad.

6. Do not short out power supply to test for voltage.

PART NUMBER TYPE

2A0836-01 HOSIZAKI-001 (Control Products - 8 Pin)

or 2A1410-01 HOS-001A (Control Products - 10 Pin)

Features of Control Products “E” Controller Board

1) Maximum Water Supply Period - 6 minutes

Water Solenoid Valve opening, in the Defrost (Harvest) Cycle, is limited by the defrost

timer. The Water Valve cannot remain open longer than the maximum period. The

Water Valve can close in less than six minutes if the defrost cycle is completed.

11

2) Defrost Timer

The defrost cycle starts when the Float Switch opens and completes the freeze cycle.

But the Defrost Timer does not start counting until the Thermistor senses 48°F at the

Evaporator outlet. The period from the end of the freeze cycle up to the point of the

Thermistor's sensing varies depending on the ambient and water temperatures.

3) High Temperature Safety - 127 ± 7°F

The temperature of the suction line in the refrigerant circuit is limited by the High Tem-

perature Safety.

During the defrost cycle the Evaporator temperature rises. The Thermistor senses 48°F

and starts the Defrost Timer. After the Defrost Timer counts down to zero, the normal

freeze cycle begins. If the Evaporator temperature continues to rise, the Thermistor will

sense the rise in temperature and at 127 ± 7°F the Thermistor operates the High Tem-

perature Safety.

This High Temperature Safety shuts down the circuit and the icemaker automatically

stops. To reset the safety, turn the power off and back on again.

This High Temperature Safety protects the unit from excessive temperature. The Control

Board will Beep every 3 seconds. The white Reset Button on the Control Board must be

pressed with power on to reset the Safety.

4) Low Water Safety

If the Pump Motor is operated without water, the mechanical seal can fail. To prevent this

type of failure, the Controller Board checks the position of the Float Switch at the end of

the initial one minute water fill cycle and at the end of each defrost cycle.

If the Float Switch is in the up position (electrical circuit closed), the Controller Board

changes to the ice making cycle. If the Float Switch is in the down position (electrical

circuit open), the Controller Board changes to a one minute water fill cycle before starting

the ice making cycle. This method allows for a Low Water Safety shut down to protect

the Water Pump from mechanical seal failure.

For water-cooled model, if the water is shut off, the unit is protected by the High Pressure

Switch.

5) High Voltage Cut-out

The maximum allowable supply voltage of this icemaker is limited by the High Voltage

Cut-out.

If miswiring (especially on single phase 3 wire models) causes excessive voltage on the

Controller Board, the High Voltage Cut-out shuts down the circuit in 3 seconds and the

icemaker automatically stops. When the proper supply voltage is resumed, the icemaker

automatically starts running again. The Control Board will signal this problem using 7

Beeps every 3 seconds.

6) LED Lights and Audible Alarm Safeties

The red LED indicates proper control voltage and will remain on unless a control voltage

12

problem occurs. At startup a 5 second delay occurs while the board conducts an internal

timer check. A short beep occurs when the power switch is turned ON or OFF.

The green LED’s 1-4 represent the corresponding relays and energize and sequence 5

seconds from initial startup as follows:

Sequence Step LED’s on Length: Min. Max. Avg.

1 Minute Fill Cycle LED4 60 sec.

Harvest Cycle LED1, 4, & 2 2 min. 20 min. 3-5 min.

Freeze Cycle LED1 5 min. 60 min. 30-35 min.

Reverse Pump Out LED1, 3, & 2 10 sec. 20 sec. Factory set.

{LED 1 – Comp; LED 2 - HGV/CFM; LED 3 – PM; LED 4 - WV}

The built in safeties shut down the unit and have alarms as follows:

1 beep every 3 sec. = High Evaporator Temperature >127 ° F.

Check for defrost problem (stuck HGV or relay), hot water entering unit, stuck headmas-

ter, or shorted thermistor.

2 beeps every 3 sec. = Defrost Back Up Timer. Defrost >20 minutes.

Orange LED marked 20 MIN energizes.

Check for open thermistor, HGV not opening, TXV leaking by, low charge, or inefficient

compressor.

3 beeps every 3 sec. = Freeze Back Up Timer. Freeze > 60 minutes.

Yellow LED marked 60 MIN energizes.

Check for F/S stuck closed (up), WV leaking by, HGV leaking by, TXV not feeding prop-

erly, low charge, or inefficient compressor.

To manually reset the above safeties, depress white alarm reset button with the power

supply ON.

6 beeps every 3 sec. = Low Voltage. Voltage is 92 Vac or less.

7 beeps every 3 sec. = High Voltage. Control voltage > 147Vac ±5%.

The red LED will de-energize if voltage protection operates.

The voltage safety automatically resets when voltage is corrected.

The Output Test switch “S3” provides a relay sequence test. With power OFF, place S3

ON and switch power to ICE. The correct lighting sequence should be none, 2, 3, 4, 1, &

4, normal sequence every 5 seconds. S3 should remain in the “OFF” position for normal

operation.

The application switch located between relay X3 & X4 must be set to match the original

board application. Place this switch in the ALP position if there is no white wire supplied

13

(Control Products HOSHIZAKI001 Board)

to the K1 connector. If there is a white wire, place the switch in the C position. If this

switch is placed in the wrong position either the compressor contactor will remain ener-

gized with the control switch OFF or the unit will not start.

The dip switches should be adjusted per the adjustment chart published in the Tech

Specs book. 7 & 8 must remain in the OFF position.

14

(Control Products HOS-001A Board)

15

[c] SEQUENCE

1st Cycle

16

2nd Cycle and after with pump drain

17

2nd Cycle and after with no pump drain

18

DIP SWITCH NO. 1 2 3 4 5 6 7 8 9 10

KM-1600MRF/3 OFF OFF ON OFF ON ON OFF OFF OFF ON

[d] CONTROLS AND ADJUSTMENTS

The Dip Switch is factory-adjusted to the following positions:

Switch Nos. 1 and 2:

Used for adjustment of the Defrost Timer.

The Defrost Timer starts counting when the Thermistor reads a certain temperature

at the Evaporator outlet.

Switch Nos. 3 and 4:

Used for adjustment of the Drain Timer.

When a freeze cycle is completed, the Pump Motor stops, and the icemaker

resumes operation in 2 seconds. Then the Pump Motor drains the Water Tank

for the time determined by the Drain Timer. The Drain Timer also determines the

time to restrain completion of a defrost cycle, i.e. the minimum defrost time.

Switch Nos. 5 and 6:

Used for adjustment of the Drain Counter.

The Pump Motor drains the Water Tank at the frequency determined by the Drain

Counter.

Switch Nos. 7 and 8:

Used only for checking the Controller Board. Usually set in OFF position.

Switch Nos. 9 and 10:

Used for adjustment of Freeze Timer.

The Freeze Timer determines maximum

freeze cycle time. Upon termination of

Freeze Timer, machine initiates the

harvest cycle. After 2 consecutive timer

terminations, machine will shut down,

possibly indicating a problem.

19

1) Defrost Control

A thermistor (Semiconductor) is used for a defrost control sensor. The resistance var-

ies depending on the Suction Line temperatures. The Thermistor detects the tempera-

ture of the Evaporator outlet to start the Defrost Timer. No adjustment is required. If

necessary, check for resistance between Thermistor leads, and visually check the

Thermistor mounting, located on the Suction Line next to the Evaporator outlet.

Temperature (°F) Resistance (kΩ)

0 14.401

10 10.613

32 6.000

50 3.871

70 2.474

90 1.633

Check a thermistor for resistance by using the following procedures.

(i) Disconnect the connector K3 on the board.

(ii) Remove the Thermistor. See “V. 11. REMOVAL AND REPLACEMENT OF THER-

MISTOR.”

(iii) Immerse the Thermistor sensor portion in a glass containing ice and water for 2 or 3

minutes.

(iv) Check for a resistance between Thermistor leads.

Normal reading is within 3.5 to 7 kΩ. Replace the Thermistor if it exceeds the normal

reading.

2) Defrost Timer

No adjustment is required under normal use, as the Defrost Timer is adjusted to the

suitable position. However, if necessary when all the ice formed on the Evaporator

does not fall into the bin in the harvest cycle, adjust the Defrost Timer to longer setting

by adjusting the Dip Switch (No. 1 & 2) on the Controller Board.

SETTING TIME

Dip Switch Dip Switch

No. 1 No. 2

OFF OFF 60 seconds

ON OFF 90 seconds

OFF ON 120 seconds

ON ON 180 seconds

20

3) Drain Timer

The Drain Timer is factory-adjusted, and no adjustment is required.

SETTING TIME

Dip Switch Dip Switch

No. 3 No. 4 T1 T2

OFF OFF 10 seconds 150 seconds

ON OFF 10 seconds 180 seconds

OFF ON 10 seconds 120 seconds

ON ON 20 seconds 180 seconds

T1: Time to drain the Water Tank

T2: Time to restrain defrost completion

4) Drain Counter

CAUTION

Do not adjust the Drain Counter, or the Evaporator may freeze up.

The Drain Counter is factory-adjusted to drain the Water Tank every 10 cycles, and no

adjustment is required. However, where water quality is bad and the icemaker needs a

pump drain more often, the Drain Counter can be adjusted as shown in the table below:

SETTING FREQUENCY

Dip Switch Dip Switch

No. 5 No. 6

OFF OFF every cycle

ON OFF every 2 cycles

OFF ON every 5 cycles

ON ON every 10 cycles

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